fix(async): retry failed error finalization

Allow error finalization to retry after a non-error completion and fallback both fail, and always persist failed/error semantics for completeWithError.

Author: test

apps/sim/lib/logs/execution/logging-session.test.ts

@@ -58,12 +58,13 @@ describe('LoggingSession completion retries', () => {
     vi.clearAllMocks()
   })
 
-  it('keeps completion best-effort when full completion and fallback both fail', async () => {
+  it('keeps completion best-effort when a later error completion retries after full completion and fallback both fail', async () => {
     const session = new LoggingSession('workflow-1', 'execution-1', 'api', 'req-1')
 
     completeWorkflowExecutionMock
       .mockRejectedValueOnce(new Error('success finalize failed'))
       .mockRejectedValueOnce(new Error('cost only failed'))
+      .mockResolvedValueOnce({})
 
     await expect(session.safeComplete({ finalOutput: { ok: true } })).resolves.toBeUndefined()
 
@@ -73,7 +74,8 @@ describe('LoggingSession completion retries', () => {
       })
     ).resolves.toBeUndefined()
 
-    expect(completeWorkflowExecutionMock).toHaveBeenCalledTimes(2)
+    expect(completeWorkflowExecutionMock).toHaveBeenCalledTimes(3)
+    expect(session.hasCompleted()).toBe(true)
   })
 
   it('reuses the settled completion promise for repeated completion attempts', async () => {
@@ -90,6 +92,66 @@ describe('LoggingSession completion retries', () => {
     expect(completeWorkflowExecutionMock).toHaveBeenCalledTimes(2)
   })
 
+  it('starts a new error completion attempt after a non-error completion and fallback both fail', async () => {
+    const session = new LoggingSession('workflow-1', 'execution-3', 'api', 'req-1')
+
+    completeWorkflowExecutionMock
+      .mockRejectedValueOnce(new Error('success finalize failed'))
+      .mockRejectedValueOnce(new Error('cost only failed'))
+      .mockResolvedValueOnce({})
+
+    await expect(session.safeComplete({ finalOutput: { ok: true } })).resolves.toBeUndefined()
+
+    await expect(
+      session.safeCompleteWithError({
+        error: { message: 'late error finalize' },
+      })
+    ).resolves.toBeUndefined()
+
+    expect(completeWorkflowExecutionMock).toHaveBeenCalledTimes(3)
+    expect(completeWorkflowExecutionMock).toHaveBeenLastCalledWith(
+      expect.objectContaining({
+        executionId: 'execution-3',
+        finalOutput: { error: 'late error finalize' },
+      })
+    )
+    expect(session.hasCompleted()).toBe(true)
+  })
+
+  it('persists failed error semantics when completeWithError receives non-error trace spans', async () => {
+    const session = new LoggingSession('workflow-1', 'execution-4', 'api', 'req-1')
+    const traceSpans = [
+      {
+        id: 'span-1',
+        name: 'Block A',
+        type: 'tool',
+        duration: 25,
+        startTime: '2026-03-13T10:00:00.000Z',
+        endTime: '2026-03-13T10:00:00.025Z',
+        status: 'success',
+      },
+    ]
+
+    completeWorkflowExecutionMock.mockResolvedValue({})
+
+    await expect(
+      session.safeCompleteWithError({
+        error: { message: 'persist me as failed' },
+        traceSpans,
+      })
+    ).resolves.toBeUndefined()
+
+    expect(completeWorkflowExecutionMock).toHaveBeenCalledWith(
+      expect.objectContaining({
+        executionId: 'execution-4',
+        finalOutput: { error: 'persist me as failed' },
+        traceSpans,
+        level: 'error',
+        status: 'failed',
+      })
+    )
+  })
+
   it('marks paused completions as completed and deduplicates later attempts', async () => {
     const session = new LoggingSession('workflow-1', 'execution-1', 'api', 'req-1')
 

apps/sim/lib/logs/execution/logging-session.ts

@@ -409,6 +409,8 @@ export class LoggingSession {
         costSummary,
         finalOutput: { error: message },
         traceSpans: spans,
+        level: 'error',
+        status: 'failed',
       })
 
       this.completed = true
@@ -919,6 +921,7 @@ export class LoggingSession {
       )
     } catch (fallbackError) {
       this.completing = false
+      this.completionAttemptFailed = true
       logger.error(
         `[${this.requestId || 'unknown'}] Cost-only fallback also failed for execution ${this.executionId}:`,
         { error: fallbackError instanceof Error ? fallbackError.message : String(fallbackError) }